MAY 10TH, 2013 RIT MSDII Final Product Design Presentation P13265 Motorcycle Safety Lighting Backpack Team
Feb 24, 2016
MAY 10TH, 2013RIT MSDII
Final Product Design PresentationP13265 Motorcycle Safety Lighting Backpack Team
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MSD Team Primary Customers:
Sport bike/standard riders who ride with backpacks
Surrogate Customer Andrew Nauss
Faculty Guides: Leo Farnand Vince Burolla
Team Members: Mike Baer, Project Manager Tyler Davis, Lead Engineer Ben Shelkey, ME Project Engineer TJ Binotto, EE Project Engineer Eric Dixon, EE Project Engineer Killian Castner, Industrial Designer
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Today’s Agenda
I. Overview 3 mins, 2 slides
I. Project Description RecapII. Customer Needs
II. System Model Design 5 mins, 4 slides
I. Final DesignIII. Testing 3 mins, 2 slides
I. Functionality vs. Test PlanIV. Project Management Review 8 mins, 2
slidesI. Schedule vs. MSDII PlanII. Budget vs. Planned Budget
V. Next Steps 10 mins, 6 slides
I. Lessons LearnedII. Next StepsIII. Moving Forward, Comments
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Concept Summary
Problem: Want to reduce number of motorcycle accidents and deaths caused by other motorists
Solution: Visibility product aimed at increasing safety of motorcycle rider
Design: Backpack with LED turn signals, brake, and running lights that operate wirelessly with vehicle
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Customer Needs
Final DesignBackpack
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Electronics Box Inside Bottom Backpack Compartment
Turn Signals
Brake/Running Lights User Control
Panel On Chest Strap
Zipper attachment to hard-shell
Soft back and straps cut from existing backpack
Lower compartment for electronics housing
“Quick” access pouch
Final DesignChest Strap User Control Panel
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Control Panel (w/ Cover)
Control Panel PCB
Hazard Button
StatusLEDs
Battery Health LEDs On/Off Button
Light Brightness High/ Low Button
Concept to Creation- Changes and Problems:• Rapid prototyped instead of vacuum formed• Battery LED colors changed• LED push buttons are not two position (light up all the
time)• Buttons not waterproof
Concept to Creation-Changes and Problems:• Housing container thicker than design• Low voltage battery shut-off non-functional
Final DesignElectronics Housing*
8NiMH rechargeable battery
40 pin ribbon connector for light signals
USB chargingport
Motorcycle Battery“Quick” ConnectPort
AC NiMH ChargerPort
Receiver XBeeOn/Off Power Button
Flash Pattern Select Push Buttons* Lid Not Pictured
Final DesignMotorcycle
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Transmitter Box
(Inside Box)Transmitter Board
w/ Xbee Transmitter
Bike Power
Bike Light Signals In
Wireless Light Signals Out
Bergquist Thermal Adhesive
Concept to Creation-Changes and Problems:• No standoffs used due to Bergquist donation• Board resized due to box being too small• Box is unnecessarily tall
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Test Results
*N/C= not completed
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Test Results
*N/C= not completed
Schedule vs. Plan12
Major Milestones:
Milestone Planned Actual Gap
Shell Formed Week 3 Week 7 1 month
Backpack Assembly Complete
Week 6 Week 9 3 weeks
Electronics Housing Complete
Week 3 Week 7 1 month
Successful Operation of Boards
Week 2 Week 11? ~ 2.5 months
Installation on Vehicle Week 6 Week 11? 1 month
Project Budget vs. Plan13
• Initial budget set to $500• Increased to $1,000
• Team spent ~$1,200
• Unexpected/ high item costs:• 3 revisions of PCB’s with new components:
• 1st $100 (budgeted for)• 2nd $90 (not budgeted for)• 3rd $150 (budgeted for in budget increase)
• Mistakes• 1 Xbee units shorted ~$20• Light covers knocked off chest strap buttons ~$10• Etc.
• Team meeting to divide costs among responsible members
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Lessons Learned: Mechanical
Shell Assembly: Problem: Thermoforming process did not create ideal
results Reason: Did not test assumptions about process Lesson: Confirm manufacturing method limitations
prior to final designBackpack Oversized:
Problem: Backpack is too large for average person to wear
Reason: CAD models not accurate prior to build Lesson: Print out CAD models to scale, check for
tolerances between assemblies
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Lessons Learned: Electrical
Board layout: Problem: Major mistakes made in 2 board layouts Reason: Lack of attention to detail during review Lesson: A systematic, thorough approach is necessary to
prevent careless, costly, and time-consuming mistakesSoftware:
Problem: Software is not fully developed, which prevented full functionality (e.g. PWM and high/low functionality)
Reason: Poor planning/ uneven work distribution Lesson: Make more refined deadlines/ don’t
underestimate the complexity of software development
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Lessons Learned: Group Dynamics
Planning: Problem: Almost every major milestone missed Reason: Did not follow MSDII plan, lack of motivation Lesson: Plans are there for a reason, use them
Communication: Problem: Disconnect/ lack of communication between
team members Reason: Not always prompt in responses, not asking
questions Lesson: Communicate frequently
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Next Steps
Next Week: Populate new board next week (upon arrival) Complete all electronics testing Install and test system on motorcycle
This summer: Will present at RIT’s technology tent at the Wegman’s
LPGA tournament
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Future Improvements
Mechanical: Redesign for smaller size More precise manufacturing process
Electrical: Complete software functionality Change battery and wireless technologies
Overall Product: Redesign for mass production Reduce build cost
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Thank You for Your Time!
Questions?